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Owner’s Operation and Installation Manual for the ES38 (RHFE-1004RFA) Energysaver Gas Direct Vent Wall Furnace Table of Contents ........... 2 Safety Information .......... 3 Operating Instructions .... 6 Care and Maintenance ... 10 Fault Codes .................... 12 Installation Instructions ... 14 Parts List ........................ 31 Consumer Support ......... 42 WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. — Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. — WHAT TO DO IF YOU SMELL GAS • • • • Do not try to light any appliance. Do not touch any electrical switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. If you cannot reach your gas supplier, call the fire department. — Installation and service must be performed by a qualified installer, service agency or the gas supplier. INSTALLER: Leave this manual with the appliance. CONSUMER: Retain this manual for future reference. Register your product at www.rinnairegistration.com or call 1-866-RINNAI1 (746-6241) This appliance may be installed as an OEM installation in a manufactured home (USA only) or mobile home and must be installed in accordance with the manufacturer’s instructions and the Manufactured Home construction and Safety Standard, Title 24 CFR, Part 3280, in the United States, or the Mobile Home Standard, CAN/CSA Z240 MH Series, in Canada. This appliance is only for use with types of gas indicated on the rating plate. A conversion kit is supplied with the appliance. This appliance may be installed in an aftermarket, permanently located, manufactured home (USA only) or mobile home, where not prohibited by local codes. This appliance is only for use with the type of gas indicated on the rating plate. This appliance is not convertible for use with other gases, unless a certified kit is used. Table of Contents Consumer Safety Information Safety Definitions ............................................. 3 Safety Behaviors and Practices ....................... 3 Safety Features ................................................ 4 Specifications Appliance Specifications .............................. 4, 5 Features ........................................................... 5 Flue Manifolds .................................................. 5 Operating Instructions Getting to Know your New Heating Appliance 6 Control Panel ................................................... 7 Operating the Heater .................................. 8, 9 Care and Maintenance................................... 10 Before Making a Service Call......................... 11 Fault Codes .................................................... 12 Restart Function ............................................. 13 Troubleshooting ............................................. 13 Installation Instructions General Instructions....................................... 14 Gas Connection ............................................. 15 Clearances to Combustibles.......................... 15 Flue Terminal Clearances ....................... 16, 17 Dimensions .................................................... 18 Installation Parts ........................................... 19 Drilling Flue Hole ........................................... 20 Attach Wall Brackets...................................... 20 Attach Back Spacers ..................................... 20 Flue Manifold Installation ......................... 21, 22 Extension Kit Installation .......................... 23-25 Connecting the Appliance .............................. 26 Operating Instructions ................................... 27 Cut-Away Diagram ......................................... 28 Wiring Diagram .............................................. 29 Ladder Diagram ............................................. 30 Parts List ................................................... 31-41 Consumer Support Warranty Information ..................................... 42 Limited Warranty...................................... 42, 43 Rinnai Corporation ES38 Manual Consumer Safety Information Safety Definitions This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others. DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices. Safety Behavior and Practices WARNING • Repairs should be performed by a qualified service technician. Consumer should not repair by yourself. • Keep the area around the appliance clear and free from combustible materials, gasoline, and other flammable vapors and liquids. • Never store liquid propane containers indoors. • Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water. • This appliance is equipped with a three-prong plug for your protection against shock hazard and should be plugged directly into a properly grounded three-prong receptacle. Do not cut or remove the ground prong from this plug. • Any alteration to the appliance or its controls can be dangerous. • Do not operate appliance with the panels removed, cracked or broken. Replacement of the panels should be done by a licensed or qualified service person. CAUTION • Do not block the warm air discharge. Do not allow anyone to sleep directly in front of the appliance. • Due to high temperatures, the appliance should be located out of traffic and away from furniture and draperies. • Children and adults should be alerted to the hazards of high surface temperature and should stay away to avoid burns or clothing ignition. • Young children should be carefully supervised when they are in the same room as the appliance. • Do not insert items into the louvers. • Do not spray aerosols near the appliance while it is operating. Most aerosols contain butane gas which is flammable. • Do not unplug the appliance while it is operating or while the fans are on. • Do not use bare hands to touch the front louvers due to high temperatures which may cause burns. • Clothing or other flammable material should not be placed on or near the appliance. • Any safety screen or guard removed for servicing must be replaced prior to operating the appliance. Rinnai Corporation ES38 Manual Safety Features • Overheat: The appliance will automatically shut down when the appliance exceeds a predetermined temperature. • Power Surge Fuse: A glass fuse on the PC board protects against overcurrent. If the fuse blows then all indicator lamps will be off. • Flame Failure: The appliance will automatically shut down if the burner flame is extinguished. • Spark Detector: The appliance automatically shuts down if there is an abnormal spark at ignition. • Power Failure: The appliance will cut off the gas if it loses electrical power. • Fusible Link: In case the overheat feature prevents the temperature from rising then the fusible link will break shutting off the appliance. Specifications Appliance Specifications Application For manufactured home (USA only) or mobile home or residential installation convertible for use with natural gas and liquefied petroleum gases (propane / LPG) when provision is made for the simple conversion from one gas to the other. For commercial setting. For installation at altitudes up to 10,200 feet (3109 m). General Description Forced combustion, forced convection, flued gas furnace Operation Push button electronic Gas Connection 1/2 in NPT Gas Control Electronic Burners Stainless steel Bunsen burner Temperature Control Electronic thermostat Ignition System Electronic spark ignition Flue System The flue must be terminated to atmosphere with only flue components listed with the appliance’s certification. Warranty will be voided if non listed components are installed. Humidifier Tray Capacity - 7 pints (3000 cc) Electrical Connection AC 120V, 60 Hz, 121 watts Weight 90 lbs (41 kg) Noise Level 37-47 dB AFUE Rating Natural Gas: 80.6% Propane: 82.0% Rinnai is continually updating and improving products. Therefore, specifications are subject to change without prior notice. The efficiency rating of this appliance is a product thermal efficiency rating determined under continuous operating conditions and was determined independently of any installed system. Rinnai Corporation ES38 Manual Appliance Specifications Natural Gas Propane Gas Minimum supply gas pressure 5.0 in (127 mm) W.C. 11.0 in (280 mm) W.C. Maximum supply gas pressure 10.5 in (267 mm) W.C. 13.0 in (330 mm) W.C. BTU/hour input Low 10,500 High 38,400 Low 10,500 High 36,500 BTU/hour output Low 8,400 High 30,720 Low 8,400 High 29,200 Features • Restarts automatically when ignition or combustion fails. • Clean the Air Filter - Indicator Lamp • Clean Heating Forced Flue Type • Humidifier Tray • Easy Operation One-Touch Ignition • Energy Saving Economy Setting • Air Flow Directional Louvers • Sensible Temperature Control Feature • Direct Vent Easily Installed • Comfortable Room Temperature Control and Display • Proportional Heating Variable Capacity • Hush! Quiet Operation • Warm Air Outlet at Floor Level (keeps your feet warm) • Modern Design Minimizes Floor Space Requirements • Function Lock • Fault Code Message Display • Room Temperature Setting Memory Flue Manifolds The following flue manifold sizes are available for different wall thicknesses: Name Kit No. fits walls S Vent Kit FOT-150 3 - 4 1/2 in (75 - 115 mm) A Vent Kit FOT-151 4 1/2 - 9 1/2 in (115 - 240 mm) B Vent Kit FOT-152 9 1/2 - 15 3/4 in (240 - 400mm) C Vent Kit FOT-153 15 3/4 - 23 5/8 in (400 - 600 mm) D Vent Kit FOT-154 23 5/8 - 31 1/2 in (600 - 800 mm) Rinnai Corporation ES38 Manual Operating Instructions Getting to know your new heating appliance CONTROL PANEL OPERATION/TEMPE RATURE CONTROL DISPLAY FILTER LAMP OPERATION LAMP WARM AIR OUTLET RATING PLATE MODEL NUMBER, SERIAL NUMBER, GAS TYPE, ETC. HUMIDIFIER OPEN THE DOOR AND POUR WATER INTO THE TRAY. AIR FILTER GAS CONNECTION 1/2" NPT THERMISTOR EXHAUST PIPE POWER CORD VENT TERMINAL COMBUSTION/ EXHAUST PLUG 120V AC COMBUSTION AIR INTAKE HOSE Rinnai Corporation ES38 Manual Control Panel All buttons beep when operated. TEMPERATURE DISPLAY SHOWS EITHER THE TEMPERATURE OR CODED ERROR MESSAGES. ON/OFF BUTTON Easy operation One touch ignition ޛCONTROL PANEL ޜ Set Temp Room Temp Temp Control Economy ON/OFF Function Lock FILTER LAMP Flashes when filter is dirty. TEMPERATURE BUTTONS " " adjust temp. to lower setting. " " adjust temp. to a higher setting. > FUNCTION LOCK Lamp is "green" when this feature is on. > ENERGY SAVING BUTTON Lamp is "green " when this feature is activated. OPERATION LAMP This lamp turns "green" when power is on. Lamp will change to "red" when burner is on. ޛINDICATOR DISPLAY ޜ Filter Rinnai Corporation ES38 Manual ON Operating the Heater Turning the heater ON When you press and release the ON/OFF button, the Temperature Level lamps will illuminate, the combustion fan will begin to run, and the spark will ignite the main burner. Adjusting the Temperature Set Temp ON/OFF This heater has an automatic ignition system. When the main burner has lit, the combustion lamp will glow red, and the spark will stop. If ignition does not occur after 15 seconds, the appliance will automatically turn off and the Temperature Level lamps will flash indicating a fault code. This may occur when using the appliance for the first time or if it has not been used for a while. Try operating the appliance again. There may be a smell of burning dust or oil the first time the heater is lit or when the heater has been out of operation for a long time. The appliance may make noises after ignition or when it is turned off. This is normal and is due to the thermal expansion or contraction of its components. Room Temp Temp Control Function Lock The first time that the appliance is turned on, the preset temperature of 72° F will be shown on the display. Every time the temperature setting is changed, that temperature setting will be the latest data appearing on the display the next time the appliance is turned on. To change the temperature setting, adjust the temperature control buttons until the desire setting is indicated. When the desired temperature has been set, 10 seconds later, the display will show the current room temperature. The thermostat automatically modulates the burner and the fan to maintain the temperature setting. The temperature settings available are: • LO - burner is on minimum combustion • 60° F - 80° F in two degree increments • HI - burner is on maximum combustion Turning the heater OFF Economy Mode Press the ON/OFF button. Do not turn off by unplugging at the power outlet. Pressing the Economy button will cause the appliance to go into Economy Mode and the green lamp will glow. This results in the temperature setting being reduced by 2° F, 30 minutes after the Economy room temperature has reached the temperature setting. After another 30 minutes the temperature setting is reduced another 2° F. This could result in the temperature setting being reduced by a maximum of 4° F. The intent of this mode is to save energy. The fan will continue to run for a short time to prevent the internal components from overheating. ON/OFF When the heater is running at the LO setting, the Economy Mode does not function. Rinnai Corporation ES38 Manual Operating the Heater Lock Sensible Temperature Control This feature locks the buttons to prevent unintended operation. The sensible temperature control feature allows comfortable heating which matches the conditions in the room. Temp Control Press the up and down buttons to activate and the lamp Function Lock will glow. Pressing and holding the up and down buttons for two seconds will disengage the Lock. If the Lock is engaged while the unit is operating, all buttons will be disabled except for the ON/OFF button. If the Lock is engaged while the unit is off, then all buttons will be disabled. The Lock must be disengaged in order to turn the unit on. Adding Water to the Humidifier CAUTION Do not fill the tray while the appliance is in operation. Close the door after filling. The humidifier tray and surrounding area are hot when the appliance is on. To fill the tray, open the door as shown in the diagram and pour water into the tray using the spout built into the door. The air will be humidified as it passes over the water in the tray. During operation a small amount of condensation is produced in the flue system and drains into the humidifier tray. If the water overflows from the water level hole, then do not add any more water. Humidifier Tray Based on the information collected by the room temperature thermistor when the heating starts, the heating capacity is automatically adjusted to achieve a comfortable heating effect and to reach the temperature setting quickly. Filter Lamp If the filter lamp flashes during operation, check the air filter for dust. If dust is present, clean the filter. See the Care and Maintenance section. Turn the heater off before cleaning the filter. Filter ON Adjusting Air Flow Direction CAUTION Do not adjust the air flow louvers while warm air is flowing. The vertical louvers may be adjusted to move the air flow more to the right or to the left. Use a screw driver or similar object to bend each louver to the desired position. Do not bend repeatedly (no more than 5 times) or else the louver will break. The horizontal louver (which determines the vertical air flow direction) is fixed and cannot be adjusted. Max. Fill Line Access Door Pull Filler Spout Do not force door open too far. Close door during operation. Rinnai Corporation ES38 Manual Care and Maintenance Maintenance Filters All maintenance and service are to be performed by a qualified service technician, preferably one who has attended Rinnai service training classes on the Direct Vent products. Dirty filters reduce the air flow and the appliance’s ability to produce heat. The filters should be cleaned frequently during the heating season. If the filters become blocked the filter indicator lamp will flash and the appliance will beep. Eventually the appliance will turn off and the Temperature Level lamp 14 will light, indicating a fault code. The appliance should be inspected annually by a qualified service technician. More frequent cleaning may be required due to excessive lint from carpeting, bedding material, etc. It is imperative that control compartments, burners, and circulating air passage ways of the appliance be kept clean. CAUTION Prevent dust from accumulating on the power cord, side covers, and parts behind the appliance. Any screen or guard removed for servicing the appliance must be replaced prior to operating the appliance. Clean as follows: 1. Turn heat off. Allow to cool for one hour. 2. Remove the front panel by removing two screws. 3. Use pressurized air to remove dust from the main burner, heat exchanger, and fan blades. 4. Use soft dry cloth to wipe cabinet. To clean the filters, the appliance should be OFF and cool. Remove the filter and clean it using a soft dry cloth or vacuum. If the filter is greasy wash with warm soapy water, rinse, and dry completely. Visual Inspection of Flame Check that the burner flames are operating normally. The flame can be seen through the circular window through the louvers. When operating normally the burner flame should appear as long, clear, blue, stable, streaks. Yellow flames or an orange color is abnormal and maintenance is required. Do not use wet cloth or spray cleaners on the burner. The flue should be inspected annually for blockages or damage. Motors are permanently lubricated and do not need periodic lubrication. Keep fan and motor free of dust and dirt by cleaning annually. VISUAL CHECK SATISFACTORY FRONT VIEW Verify proper operation after servicing. Care of Exterior Dampen soft cloth with warm water. Wring water out well and wipe the unit. Do not use volatile substances such as benzene or thinners. They cause fading of the paint and deformation of the resin. UNSATISFACTORY Snow Accumulation Keep the area around flue terminal free of snow and ice. The appliance will not function properly if the intake air or exhaust is impeded by obstructions. Refer to the Flue Terminal Clearances. The clearance in Ref. A should be maintained from any snow accumulation. 10 AIR FILTERS Rinnai Corporation ES38 Manual FRONT VIEW Before Making a Service Call Before making a service call please check the following: At Ignition: Heater does not operate. Is the heater plugged in? Have the fuses or breaker blown at the fuse box / breaker panel? Is there a power failure? Is the air filter blocked? Is anything blocking the outlet for the hot air? Is the flue blocked? Warm air does not flow when the burner lights. The fan is started automatically after a short delay. This is to allow the heat exchanger to warm up, helping to avoid cold draughts. Smoke or strange smells are produced on the first trial light up after installation. This is caused by grease or oil and dust on the heat exchanger and will stop after a short time. Sharp clicking noises at ignition, or when unit cuts down on the thermostat, or goes out. This is simply expansion noise from the heat exchanger. During Combustion: Clunking noise when the thermostat operates. This is the sound of the solenoid gas valves opening and closing. Unit is not heating room. Is the air filter blocked? Is the set temperature high enough? Is the warm air outlet blocked by anything? Are the doors and windows of the room closed? Was the appliance correctly sized for the space? Air filter is blocked or the louvers are blocked or obstructed. Allow heater to cool, clean air filter, operate again. Heater will not re-ignite after overheating. Even after unit has cooled down, the heater does not ignite again. Repair is necessary. Contact a qualified / authorized service provider. When the unit is turned off. Convection fan continues to run after turning OFF. This is to remove the residual heat from the heat exchanger. The fan will stop when the heater cools down. Other Points: Steam is discharged from the flue terminal . High efficiency appliances tend to discharge water vapor on cold days. This is normal. Unit cuts off without apparent reason. Check whether filters are blocked. Dirty filters will cause the heater to overheat. Power Failure. Switch OFF, then ON again when power is restored to re-set controls. Rinnai Corporation ES38 Manual 11 Fault Codes If there is a malfunction the appliance may shut down as a safety precaution and display a fault code to assist in diagnosing the problem. The fault code will flash in the display on the control panel. When making a service call, this code will assist with diagnosing the fault. CODE DISPLAYED You may be able to clear the fault code by turning the heater off and then on again. If the fault code remains or returns on the next operation, contact Rinnai or your nearest service agent and arrange for a service call. FAULT REMEDY 11 Ignition Failure Check that gas is turned ON. Check that the vent termination is not blocked. Refer to the Restart Function explanation. Service call if repeated. 14 Overheat Clean filter. Service call if repeated. [1] 16 Room Overheat Lower room temperature to less than 104°F (40°C). 31 Room Temperature Sensor Faulty Service call. 34 Overheat Temperature Sensor Faulty Service call. 49 Sensor Breakdown Service call. 53 Sparker Failure Ser vic e cal l. 61 Combustion Fan Failure Service call. 70 Faulty ON/OFF Switch Service call. 71 Faulty Solenoids Service call. 72 F a u lt y F l a m e R o d Service call. 73 Communication Error Turn heater OFF, then ON again. 99 Flue Block Check around the flue terminal for blockage. [2] 32 33 [1] If the fusible link needs replacement, it must be done by a qualified service agency. In addition, the cause of the overheat needs to be determined. The fusible link is a one use safety device that breaks to shut off the appliance. [2] Remove any obstructions. The flue needs to be kept clear to expel exhaust gases. If the appliance fails to operate contact a qualified service agency. 12 Rinnai Corporation ES38 Manual Restart Function If the appliance fails to ignite, the appliance will attempt ignition after 1 hour. The “Ignition Failure” fault code, 11, will appear during that hour and disappears after a successful ignition. If ignition fails again, then the fault code will remain and another attempt to ignite will occur in 1 hour. The fault code is not stored in the fault code history. If the flame is extinguished during forced combustion then the appliance will attempt ignition after 1 hour. The “Ignition Failure” fault code, 11, will appear during that hour and disappears after a successful ignition. Forced combustion takes place for about 15 seconds after ignition. After this time, the temperature control logic controls the combustion. If the flame is extinguished (burner combustion failure) while the temperature control logic is operating the appliance, then the appliance will immediately attempt ignition. No fault code will appear. Takes too long to warm the room Noisy ignition Smell of gas Combustion stops during operation Unusual combustion Cause No ON indicator Problem Burner doesn’t ignite Troubleshooting Remedy Not Plugged In Plug In Power Failure Push On/Off button to attempt restart after power is restored. (Initial Installation) Air In Gas Pipe Purge air (Installer) Gas Filter Blocked Service Call Miss Ignition Service Call Flue terminal obstructed Clear obstruction Flue manifold not connected Service Call Louver obstructed Clear obstruction Air filter blocked Clean filter Gas Escape Service Call Function Lock Set Cancel Function Lock Gas turned off at meter, tank, or valve. Turn gas on Rinnai Corporation ES38 Manual 13 Installation Instructions General Instructions WARNING • This appliance discharges a large volume of warm air next to the floor. Any particles in the air such as cigarette smoke could cause discoloration in nylon carpets containing dyes or vinyl surfaces. Do not use substitute materials. Use only parts certified with the appliance. • A qualified service technician should install the appliance and inspect it before use. • If you move, check the gas type in your new area. The local gas authority will be able to advise on local regulations. • The installation must conform with local codes or, in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CSA B149.1. • A manufactured home (USA only) or mobile home OEM installation must conform with the Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280, or, when such a standard is not applicable, the standard for Manufactured Home Installations, ANSI/NCSBCS A225.1, or the standard for Gas Equipped Recreational Vehicles and Mobile Housing, CSA Z240.4. • The appliance, when installed, must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70, or the Canadian Electrical Code, CSA C22.1. • Appliance input ratings are based on sea level operation and need not be changed for operation up to 2000 ft (609.9 m) elevation. For operation at elevations above 2000 ft (609.9 m), refer to the Conversion Manual. • The appliance and its appliance main gas valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.5 kPa). • The appliance must be isolated from the gas supply piping system by closing its equipment shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.5 kPa). • This appliance is not designed to built in. • This appliance is only for use with the type of gas indicated on the rating plate. This appliance is not convertible for use with other gases unless a certified kit is used. If conversion of the unit is needed, conversions must be performed by a qualified service provider at the owner’s expense. • This appliance must not be connected to a chimney flue serving a separate solid-fuel burning appliance. • Rinnai suggests that a dedicated electrical circuit with a 120VAC, 60 hz, 10 amp power source be used. • A test plug are provided for testing of manifold differential pressure. It is located on the modulating gas valve. • The appliance should be correctly sized for the space it is required to heat. • Follow the installations instructions and those in Care and Maintenance for adequate combustion and ventilation air. • The flow of combustion and ventilation air shall not be obstructed. • Clearances to access the appliance during servicing are 2 inches (50 mm) from the sides, 40 inches (1 m) from the front, and 10 inches (250 mm) from the top. NOTICE If installation is at a location above 2001 ft (610 m), then follow the Adjust Gas Pressure Settings procedure in the Conversion Manual. If installation is at or below 2000 ft (610 m) then the pressure settings do not need to be adjusted. • If the flooring is carpet, tile, or other combustible material other than wood, then the appliance must be installed on a metal or wood panel extending the full width and depth of the appliance. 14 Rinnai Corporation ES38 Manual Gas Connection WARNING When connecting the gas valve or other gas components in the gas line, use a backup wrench to ensure the connection is gas tight. • The gas supply line shall be gas tight, sized and so installed as to provide a supply of a gas sufficient to meet the maximum demand of the heater without loss of pressure. • A shut off valve and appliance connector valve should be installed in the upstream of the gas line to permit servicing. • Flexible pipe and any appliance connector valve used for gas piping shall be types approved by nationally recognized agencies. • Any compound used on the threaded joint of the gas piping shall be a type which resists the action of liquefied petroleum gas (propane / LPG). • After completion of gas pipe connections all joints including the heater must be checked for gas tightness by means of leak detector solution, soap and water, or an equivalent nonflammable solution, as applicable. (Since some leak test solutions, including soap and water, may cause corrosion or stress cracking, the piping shall be rinsed with water after testing, unless it has been determined that the leak test solution is non-corrosive.) • Check the gas supply pressure immediately upstream at a location provided by the gas company. Supplied gas pressure must be within the limits shown in the Specifications section. • Refer to an approved pipe sizing chart if in doubt about the size of the gas line. • Install manual gas cut-off valve so that it can be accessed for easy operation. Do not conceal manual cut-off valve behind back spacer. • An elbow is supplied to attach to the gas line if needed. Clearances to Combustibles When determining where to install the appliance the clearances to combustibles shown in the figure must be followed. Also refer to the Safety Behaviors and Practices section. The clearance to combustibles from the top is zero. Rinnai recommends 10” (250 mm) clearance on both sides for servicing. 10"(250mm) 0" 2" (50mm) 2" (50mm) 40" (1m) Rinnai Corporation ES38 Manual 15 16 D E L Wall B 24” (600mm) Opposite Wall Floor (500mm) 20” 10” (250mm) Non Flammable Flammable (600mm)24” STANDARD INSTALLATION OF FLUE MANIFOLD. Diagram below shows minimum clearances and distances from obstructions. Also check local regulations. F Rinnai Corporation ES38 Manual B C OPERABLE FIXED CLOSED A G B B INSIDE CORNER DE TAIL B A J OPERABLE FIXED CLOSED B V X SNOW I M AREA WHERE TERMINAL IS NOT PERMITTTED VENT TERMINAL AIR SUPPLY INLET H Clearance in Ref. A also applies to anticipated snow line TERMINATION K Flue Terminal Clearances 20 inches (50 cm) * * 12 inches (30 cm) to nonflammables � 24 inches (60 cm) to flammables � * * 20 inches (50 cm) 3 feet (91 cm) within a height 15 feet (4.5 m) above the meter/regulator assembly 6 feet (1.83 m) 7 feet (2.13 m) � 12 inches (30 cm) to nonflammables � 24 inches (60 cm) to flammables � Vertical clearance to ventilated soffit, located above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal Clearance to unventilated soffit Clearance to outside corner Clearance to inside corner Clearance to each side of center line extended above meter/regulator assembly Clearance to service regulator vent outlet Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance Clearance to a mechanical air supply inlet Clearance above paved sidewalk or paved driveway located on public property Clearance under veranda, porch, deck, or balcony D E F G H I Rinnai Corporation ES38 Manual J K L M 12 inches (30 cm) 3 feet (91 cm) * * Clearance to permanently closed window C 3 feet (91 cm) above if within 10 feet (3 m) horizontally 9 inches (23 cm) * * * * * 9 inches (23 cm) 12 inches (30 cm) Clearance to window or door that may be opened 6 inches (15 cm) for appliances < 10,000 BTUh; 9 inches (23 cm) for appliances > 10,000 BTUh and < 50,000 BTUh, 12 inches (30 cm) for appliances > 50,000 BTUh 6 inches (15 cm) for appliances < 10,000 BTUh; 9 inches (23 cm) for appliances > 10,000 BTUh and < 50,000 BTUh, 12 inches (30 cm) for appliances > 50,000 BTUh B US Installations Canadian Installations Clearance above grade, veranda, porch, deck, or balcony. (Take into account the anticipated snow line) Description A Ref Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, clearances are in accordance with local installation codes and the requirements of the gas supplier. � ∗ � A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. Flue Terminal Clearances 17 Dimensions inches (mm) 14 1/16" (357.5) 36 5/8" (930) 12 7/16" (316) 28 7/16" (723) 7 7/8" (200) 11 13/16" (300) 4 9/16" (116) 15 5/8" (397) 10 7/8" (R277) 26 3/8" (670) Cavity Opening 6 1/2" (165) 9 13/16" (250) 23 3/8" (593) 13 3/4" (R350) 13" (330) 6 5/16"(160) 18 Rinnai Corporation ES38 Manual Installation Parts The following items are included with the appliance: Flue Manifold .......................1 Spare rubber seal...........................1 (‘A’ Flue units only) “A” Vent Kit, FOT-151 (For weatherboard installations) Back Spacer Set Wall Brackets 2 Insulation Clip 1 Plastic tie for air inlet 1 (M4) 7 1 For Back Spacer Set Vent adaptor 1 (M5) 4 For Wall Brackets Pipe stopper A&S 2 (M4× 20) Pipe stopper E 1 (M4) Manual Valve Set 1 Elbow(gas) 1 For Flue Lock Stopper 1 3 For Flue Manifold (M4.8× 32) Wood Screws Rinnai Corporation ES38 Manual Wall Bracket Screws Owner’s Manual Conversion Manual Template 7 1 19 Drilling Flue Hole Ensure that there are no gas or water lines, or electrical circuits in the wall location where the flue hole is to be drilled. Flue Hole 3 1/8" (80 mm) Drill the flue hole using a 3 1/8 inch (80 mm) drill. A template is provided. The center of the hole must be located anywhere within the shaded area, unless extension kits are used. See the dimensions diagram. For weatherboard walls, drill through the center of the weatherboard from the outside first and then through the plasterboard. Attach Wall Brackets Attach the wall brackets as shown. A template is provided. 723 30 593 24 Wall bracket Attach Back Spacers Attach side back spacers to both sides of the appliance with 2 screws each. FILT ER FILT ER B FLU Flexible Plactic Hose (C) 20 Rinnai Corporation ES38 Manual EM AN A IFO LD Flue Manifold Installation • The flue manifold must exhaust to the outside. Do not exhaust into other rooms. • The flue manifold is not designed to be positioned under floors or below the heater. • This appliance can only be used with one of the five types of Rinnai flue kits. The flue kits and their dimensions are listed on the previous page. • Refer to the Flue Terminal Clearances section. • The termination cannot be vertical. 1. Disassemble the flue manifold The flue consists of 3 parts: Inside Connection • sleeve Terminal • inside connection • outside terminal Disassemble the flue manifold by first pulling out the inside connection. To remove the outer terminal pull and release the two internal ties and then pull out the outer terminal. Sleeve Clearance to combustibles for the sleeve and flanges is zero inches. 2. Adjust the sleeve length Measure wall thickness through previously drilled 3 1/8 inch (80 mm) hole. The end of the sleeve should protrude 3/16 3/8 inch (5-10 mm) from the outside wall. Remove extension if necessary The sleeve is threaded for adjustment. Adjust the sleeve length to wall thickness plus 3/16 3/8 inch (5-10 mm). NOTE: Do not extend beyond the red line. For other than the “S” type flue manifold, if a shorter length is necessary an extension can be removed. Cut the plastic and remove the extension. 3. Attach the sleeve Attach to the inside wall using 3 screws arranging the flange so that the marking “TOP” is at the top. The flange is offset 2° to allow the condensate drain to the outside. sleeve should extend 3/16 - 3/8 in (5-10 mm) 3 screws Rinnai Corporation ES38 Manual 21 Flue Manifold Installation 4.Install the Terminal Check that the terminal seal is in place. For weatherboard walls, add the second seal next to the terminal seal to compensate for weather board angle. Terminal seal From the outside insert the terminal into the sleeve with the marking “TOP” at the top. The left hand side locking tie should be marked “LEFT”. Terminal Locking tie 5. Lock the ties Pulling hard on the left and right hand ties, clip the ties over the notches inside the sleeve. You should be able to pull the ties 2 or 3 notches past the starting point. Cut the ties, leaving about 3/4 inch (20 mm) past the notch. Bend the ties back into the sleeve and parallel to the wall. Locking ties Sleeve 6. Insert Inside Connection Assembly Push the assembly into the terminal tube, ensuring that the seal is in place on the inner tube. Attach the inside connection with 3 screws. The inner connection can still be turned to install the screws. 3 screws 22 Rinnai Corporation ES38 Manual Extension Kit Installation If necessary, extension kits are available to extend the exhaust line and air intake hose between the manifold and the appliance. The maximum vent length is 13 feet (4 m) with 2 bends. The bent pipe attached to the appliance does not count toward the max limit of 2 bends. Do not allow any low points in the exhaust line where condensate will collect. Vent extensions installed in unconditioned air space must be insulated with high temperature insulation and must be accessible. Vent extensions must not be concealed per NFPA 54 and must be accessible allowing inspection and repair. Decorative covers are available from Rinnai. Examples INCORRECT • Too many bends (limit is 2) • Air intake hose is above exhaust pipe CORRECT Rinnai Corporation ES38 Manual 23 Extension Kit Installation CAUTION Clearances Use the pipe stoppers, connectors, clamps, and screws according to these instructions in order to ensure no leakage of exhaust gases. exhaust pipe to combustibles 1 inch (25.4 mm) exhaust pipe to non-combustibles zero Clamps Exhaust pipe Exhaust pipe Both the exhaust line and air intake hose are supported by clamps which are attached to the wall. A wall fixture can be used to offset the clamp from the wall. Use Screw B to attach the wall fixture to the wall. If the wall fixture is not used then use Screw A and the nut to attach the clamp to the wall. The air intake hose should always be underneath the exhaust line so that in case the air intake hose sags it will not come into contact with the exhaust line. Air intake hose Air intake hose Installing the Exhaust Line The exhaust line is connected between the bent pipe at the rear of the heater and the exhaust port on the flue manifold. Male end Female end To connect exhaust pipes with other straight pipes or bends, fit the male end into the female end. Use pipe stopper A to clamp the connection. Pipe stopper B Pipe stopper A Use pipe stopper B to fix the length on the adjustable exhaust pipes. Do not extend these pipes beyond the red line. Do not cut the exhaust pipe. Use the adjustable pipes if necessary. To bend the elbow, insert exhaust pipes into both ends for additional leverage. Bend to desired angle. Do not straighten the bent pipe attached to the appliance. Adjust the angle Connecting the Air Intake Hose The air intake hose is connected between the air connection at the rear of the heater and the air intake port on the flue manifold. Push the air intake hose onto the flue manifold and secure with the plastic cable tie. Join air intake hoses by screwing the hose joint half of its length into the air intake hose and then screwing another air intake hose into the hose joint. The lengths of the air intake hose and the exhaust pipe must be the same in order for the appliance to operate properly. The hose can be cut to the required length. Deburr all rough edges. Do not cut the hose attached to the appliance. Support the air intake hose with pipe clamps. Hose joint air intake hoses 24 Rinnai Corporation ES38 Manual Extension Kit Installation A B Extension Kits and Parts FOT-102(11.4-20.3 inch) FOT-103(21.0-39.6 inch) EXHAUST PIPE 1 6 PIPE STOPPER A 7 PIPE STOPPER B PIPE CLAMP 12 SCREW A 13 SCREW B EXHAUST PIPE(STRAIGHT) 40 inch 2 A FOT-102(29.5 inch) B FOT-103(49.2 inch) C FOT-114(90.6 inch) 10 WALL-FIXTURE AIR INTAKE HOSE 3 8 4 9 BENT ELBOW 5 TOP STOPPER 11 NUT 14 O RING HOSE JOINT Item Description FOT-102 FOT-103 FOT-114 1 Exhaust Pipe (adjustable) 11.4-20.3 in (290-515 mm) 1 1 Exhaust Pipe (adjustable) 21.0-39.6 in (533-1005 mm) 1 1 2 Exhaust Pipe - 40 in (1016 mm) 3 Air Intake Hose - 29.5 in (750 mm) 3 Air Intake Hose - 49.2 in (1.25 m) 3 Air Intake Hose - 90.6 in (2.3 m) 4 Bent Elbow 5 Hose Joint 1 1 1 6 Pipe Stopper A 1 1 2 7 Pipe Stopper B 1 1 1 8 Top Stopper 1 1 1 9 Pipe Clamp 2 sets 3 sets 4 sets 10 Wall Fixture 2 3 4 11 Nut 2 3 4 12 Screw A 2 3 4 13 Screw B 4 6 8 14 O Ring FOT-115 1 1 1 1 1 2 1 Rinnai Corporation ES38 Manual 25 Connecting the Appliance 1. Attach flue adapter to the flue manifold with pipe stopper S. Flue Adapter Pipe stopper S Flue Manifold Plastic tie 2. Attach the air inlet hose to the flue manifold. Secure with plastic tie. The unused inlet is plugged with the rubber cap supplied on the manifold. Inlet elbow Inlet hose 3. Connect the vent sliding tube with pipe stopper S and E. The sliding tube should not be extended beyond the red line. The red line should not be visible after sliding the tube into the vent outlet. Flue Manifold Screw Sliding Tube PIPE STOPPER S PIPE STOPPER A PIPE STOPPER E 4. Slide the insulation sleeve up to the flue manifold and slip the securing clip over the sleeve as shown. 5. Attach the appliance to the wall brackets, using 2 screws at each bracket. SCREW 㧔M5㧕 6. Attach the back spacer with 3 screws to the top of the appliance. 7. If necessary, the appliance can be leveled using the adjustable legs under the front right and left legs. Up to 3/8"(10mm) Adjustable Leg 26 Rinnai Corporation ES38 Manual Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. • If you cannot reach your gas supplier, call the fire department. C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, do not try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion. D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water. OPERATING INSTRUCTIONS 1. STOP! Read the safety information above. 2. Set the thermostat to lowest setting. 3. Turn off all electric power to the appliance using the ON/OFF button. 4. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. 5. Locate the manual gas valve on the side of the heater. Turn the manual valve clockwise to the full OFF position. Manual Valve CLOSE OPEN 6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow “B” in the safety information above. If you don’t smell gas, go to the next step. 7. Turn the manual gas valve counterclockwise to the full ON position. 8. Turn on all electric power to the appliance using the ON/OFF button. 9. Set the thermostat to desired setting. 10. Combustion indicator glows red when the burner is lit and flashes when the burner fails to ignite. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier. See manual for additional information. TO TURN OFF GAS TO APPLIANCE 1. Set the thermostat to lowest setting. 2. Turn off all electric power to the appliance using the ON/OFF button. 3. Locate the manual gas valve on the side of the heater. Turn the manual valve clockwise to the full OFF position. NOTE: The fan will continue to operate until the appliance is cool. Do not turn the appliance off by unplugging it from the wall. Keep burner and control compartment clean. See installation and operating instructions. Rinnai Corporation ES38 Manual 27 Cut-Away Diagram 28 Rinnai Corporation ES38 Manual Rinnai Corporation ES38 Manual If any of the original wire as supplied with the appliance must be replaced, it must be replaced with type 18 AWG wire or its equivalent. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. CAUTION Wiring Diagram 29 Ladder Diagram 30 Rinnai Corporation ES38 Manual Parts List For replacement parts call Rinnai at 1-800-621-9419. Rinnai Corporation ES38 Manual 31 Parts List 32 Rinnai Corporation ES38 Manual Parts List Rinnai Corporation ES38 Manual 33 Parts List 147 926 924 149 148 145 150 145 146 146 924 925 152 144 904 137 140 139 138 141 107 151 109 901 910 110 111 140 139 901 141 143 142 910 712 909 712 431 909 432 34 Rinnai Corporation ES38 Manual Parts List Rinnai Corporation ES38 Manual 35 Parts List 36 Rinnai Corporation ES38 Manual Parts List Rinnai Corporation ES38 Manual 37 Parts List No DRAWING No. 001 1001F-073-9 1001F-073-4 1004F-2071-6 1004F-2071-3 1004F-2073-10 1004F-2073-6 556F-558-2 ZUAA02SZ 1001F-1514-2 1001F-1514-3 1001F-160-9 1001F-160-5 RHFE1004-0115 RHFE1004-0116 1001F-084-2 1001F-084-3 1001F-163-2 1001F-1323 1001F-162-7 1001F-162-4 1001F-164-4 1001F-1322 1001F-078 551F-015 RHF300-185-1 1001F-1410-2 1001F-1410-9 1001F-1411-4 1001F-1411-5 1001F-165-10 1001F-165-13 1004F-228 1001F-092 1004F-825 1001F-157 550F-0220 550F-0225 1004F-2111 1001F-150-3 1001F-144-3 1001F-147-3 RHF250-075 1001F-049 1004F-2022 1004F-2020 1001F-104-2 RHF250-038 1001F-216 1001F-168 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 019 020 021 022 024 025 026 027 100 101 102 103 104 105 106 107 108 109 110 38 PART NAME SIDE PANEL I SIDE PANEL D TOP PLATE F TOP PLATE C OPERATION LID J OPERATION LID F FULCRUM STOPPER DECORATION PANEL ASS’Y C DECORATION PANEL ASS’Y D FRONT PANEL ASS’Y I FRONT PANEL ASS’Y E ESCUTCHEON PANEL ESCUTCHEON PANEL B LOUVER SUPPORT TRIM B LOUVER SUPPORT TRIM C LOUVER ASS’Y B LOUVER ASS’Y BOTTOM TRIM ASS’Y G BOTTOM TRIM ASS’Y D FILLER ASS’Y D FILLER ASS’Y LOUVER DOOR HINGES FILLER MAGNET BACK SPACER LEFT A BACK SPACER LEFT E BACK SPACER B RIGHT D BACK SPACER B RIGHT E BACK SPACER UPPER ASS’Y J BACK SPACER UPPER ASS’Y M AIR FILTER ASS’Y BACK SPACER SUPPORT WALL BRACKET B LEG ASS’Y RUBBER BRACKET ASS’Y BASE SUPPORT RUBBER Lamp house HIGH BURNER LEFT ASS’Y C HIGH BURNER RIGHT ASS’Y C LOW BURNER ASS’Y C DAMPER PANEL BURNER BRACKET PACKING BURNER BRACKET LEFT ASS’Y BURNER BRACKET RIGHT ASS’Y FLAME ROD ELECTRODE CLIP ELECTRODE ELECTRODE BRACKET QTY REMARKS 1004RFA 1004RFA-W 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 4 1 1 1 1 2 2 1 1 1 1 1 1 Rinnai Corporation ES38 Manual 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 4 1 1 1 1 2 2 1 1 1 1 1 1 Parts List No DRAWING No. 111 112 113 114 115 116 117 118 119 120 121 122 123 124 126 127 129 137 138 139 140 141 142 143 144 147 148 149 150 151 152 153 154 155 157 158 159 160 161 162 163 164 165 166 167 168 169 170 1001F-175 RHF250-076 1004F-2031 1004F-2036 1001F-042 1001F-041 1004F-2066 1004F-2065 1004F-2064 M10B-4-8 1001F-101-2 CP-30488 1004F-2030 RHFE1004-0130 1001F-008-2 1001F-228 BRR37-244 1001F-138-2 RHF1000-167 300FT-14 300FT-15 1004F-2013 1001F-115 1004F-2048 1001F-142-2 1001F-143 1001F-169 1001F-021-1 1001F-021-3 1001F-183 RHF1000-174 M10B-4-49 1001F-131 1001F-132-2 1004F-530 1004F-401 1001F-250 1001F-1730 1001F-111 RHF1000-145 431F-1900 RHF1000-132 RHF1000-130-d 1004F-2032-1 1004F-2033 1004F-2052-1 1004F-2052-2 1001F-158-2 PART NAME ELECTRODE SEAL PACKING AIR SHUTTER ADJUSTMENT MAIN INJECTOR MAIN INJECTOR BURNER SHIELD LEFT BURNER SHIELD RIGHT INTERCONNECTION C ASS’Y INTERCONNECTION B ASS’Y INTERCONNECTION A ASS’Y O-RING INTERCONNECTION CLIP INTERCONNECTION BRACKET INTERCONNECTION BRACKET GAS CONTROL ASS’Y C VALVE BRACKET B REVOLVING STOPPER D ON-OFF VALVE ASS’Y MAIN HEAT EXCHANGER ASS’Y B INLET FLANGE PACKING GLASS WINDOW PACKING VIEWING GLASS GLASS CLIP BLANKING PANEL OT.TH BRACKET SUB HEAT EXCHANGER No.1 ASS’Y B SUB HEAT EXCHANGER No.2 ASS’Y SPACER SUB HEAT EXCHANGER CLIP A SUB HEAT EXCHANGER CLIP LEFT SUB HEAT EXCHANGER ASS’Y HEAT EXCHANGER BRACKET SLIP O-RING EXHAUST ELBOW ASS’Y SLIDE PIPE B EXHAUST ADAPTOR B ASS’Y SLIDE PIPE STOPPER EXHAUST PIPE STOPPER ASS’Y EXHAUST PIPE STOPPER S ASS’Y COVER ELBOW COVER STOPPER FLUE ASS’Y AIR INTAKE ELBOW AIR INTAKE FLEXIBLE HOSE AIR INLET A AIR INLET PACKING SENSING TUBE A SENSING TUBE B AIR INTAKE DUCT B QTY REMARKS 1004RFA 1004RFA-W Rinnai Corporation ES38 Manual 1 2 2 1 1 1 1 1 1 6 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 2 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 6 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 2 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 39 Parts List No DRAWING No. PART NAME 171 172 178 180 192 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 1001F-053 1001F-153-2 CP-30310 1004F-2082 1004F-2088 1001F-186 1001F-154 1001F-156 1001F-112 1001F-004-2 1001F-066 1001F-064 1001F-110 1004F-2006 ES-02051 550F-0903 1004F-308-1 1004F-308-2 1001F-152 RHF1000-89 1001F-159-2 RC-223-21-1 1001F-137 SEAL PACKING COMBUSTION FAN CASING SCREW FOR MOTOR COMBUSTION FAN TOTAL ASS’Y BUSH RE-INFORCED BOARD REAR PANEL ASS’Y FRAME LEFT ASS’Y FRAME RIGHT ASS’Y WARM AIR SEAL PACKING CONVECTION FAN SUPPORT B TOP PANEL SUPPORT FRAME CORNER TOP PANEL REINFORCEMENT FRAME CORNER ASS’Y CONVECTION MOTOR CONVECTION MOTOR BRACKET CONVECTION FAN A CONVECTION FAN B FAN CASING ASS’Y BELL MOUTH HEAT SHIELD BOARD B ASS’Y SEAL PACKING VIEWING WINDOW PANEL 419 420 421 422 423 424 425 426 427 430 431 432 433 435 436 700 702 703 704 705 706 707 708 709 710 711 712 713 714 302F-0506 1001F-062 1001F-070 1001F-217 ES-01131 1001F-172 550F-1418 1001F-037 1004F-2016 CP-90436-3 RC-312-628 RC-329-1033 1004F-2009 1004F-2085 CP-90077-1 1004F-2075 1004F-2078 EI-161 ET-251 1004F-2310 1004F-2051 CP-90466-3 1004F-2054 1004F-2053 1004F-2059 1001F-1667-3 1004F-2057 1004F-2058 1004F-2061 O.H.S. PROTECTOR ELECTRODE VIEWING PANEL ELECTRODE COVER O.H.S. BRACKET OVERHEAT SWITCH WATER LEVEL INDICATOR WATER LEVEL LABEL HUMIDIFIER TRAY TRANSFORMER BRACKET P.C.B. SUPPORT THERMISTOR HOLDER POWER SUPPLY CABLE BRACKET EDGE CONVECTION MOTOR SUB ASS’Y SPEED CLIP OPERATION P.C.B ASS’Y F INDICATOR ASS’Y IGNITOR ASS’Y TRANSFORMER MAIN P.C.B. TOTAL ASS’Y PRESSURE SENSOR POWER SUPPLY CABLE ASS’Y MOTOR LEAD ASS’Y B SENSOR LEAD ASS’Y FR LEAD ASS’Y HIGH TENSION CORD ASS’Y THERMISTOR LEAD ASS’Y SV.IG LEAD ASS’Y TF LEAD ASS’Y 40 QTY REMARKS 1004RFA 1004RFA-W 1 1 3 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2 1 2 2 1 1 3 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 4 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Rinnai Corporation ES38 Manual Parts List No DRAWING No. 800 800 801 801 802 803 804 805 806 806 807 808 809 810 810 811 812 813 814 850 851 852 853 853 854 901 902 903 904 905 906 907 908 909 910 911 912 913 914 915 916 917 918 919 920 921 922 923 924 925 926 927 CP-74167-27 CP-74167-28 CP-74168-27 CP-74168-28 RHFE1004-0112 1001F-1651 556F-2065 1001F-1656 431F-1840 431F-1841 1001F-1654 CP-72062B-2 431F-1860 431F-1862 431F-1863 431F-1830 CP-71747-2 CP-74177-5 CP-74178-5 RHFE1004-0110 RHFE1004-0111 1004F-2040 1004F-2095-3 1004F-2095-4 CP-30324 ZBA0408SC ZBA0408SZ CP-30421-1 ZBA0412SZ ZBB0410SC ZBD0408SC ZBD0408SZ ZEAB0408SZ ZEAB0408SB ZEAB0408SC ZGAA0308SZ ZAA0506SZ ZAA0420SZ ZEDB0408SZ ZHAA0408SZ ZHAD0510SC ZDAA0410SZ ZIAD0408SZ ZRAB04SZ ZSCA04SZ CP-30408 ZAA0306SZ CP-30486-2 ZSCA04SC ZRAA04SC ZAA0440UK ZIAD0410SC PART NAME RATING PLATE RATING PLATE RATING PLATE RATING PLATE OPERATION LABEL FILTER LABEL CAUTION LABEL CAUTION MARK PROPANE STICKER NG STICKER EXHAUST CAUTION LABEL SPEC MARK POWER SUPPLY CABLE LABEL GAS CHECK LABEL GAS CHECK LABEL EXHAUST CAUTION LABEL PULL LABEL RATING PLATE SUPPORT LABEL RATING PLATE SUPPORT LABEL OWNER’S MANUAL CONVERSION MANUAL TEMPLATE CONVERSION SET(TO NG) CONVERSION SET(TO LPG) MALE - FEMALE ELBOW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW NUT WASHER SCREW SCREW SCREW WASHER NUT SCREW SCREW QTY REMARKS 1004RFA 1004RFA-W Rinnai Corporation ES38 Manual 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 41 Consumer Support Warranty Information The installer is responsible for your heater’s correct installation. Please complete the information below to keep for your records: Purchased from: _________________________________________________________________ Address: _____________________________ Phone: _________________________________ _____________________________ Date of Purchase: __________________________________ Model No.: ________________________________________ Serial No.: ________________________________________ Installed by: ___________________________ Installer’s License No.: _____________________ Address: _____________________________ Phone: _________________________________ Date of Installation: __________________________________ Limited Warranty Gas Direct Vent Wall Furnace What is covered? This Warranty covers any defects in materials or workmanship, subject to the terms stated below. This Warranty extends to the original purchaser and subsequent transferees, but only while the product remains at the site of the original installation. This Warranty only extends through the first installation of the product and terminates if the product is moved or reinstalled at a new location. How long does coverage last? Item Period of Coverage Heat Exchanger 10 years from date of purchase * All Other Parts 5 years from date of purchase Reasonable Labor 2 years from date of purchase What will Rinnai do? Rinnai will repair or replace the covered product or any part or component that is defective in materials or workmanship as set forth. Rinnai will pay reasonable labor charges associated with the repair or replacement of any such part or component. All repair parts must be genuine Rinnai parts. All repairs or replacements must be performed by an individual or servicing company that is properly trained, state qualified or licensed to do the type of repair. 42 Rinnai Corporation ES38 Manual Limited Warranty - continued Replacement of the product may be authorized by Rinnai only. Rinnai does not authorize any person or company to assume for it any obligation or liability in connection with the replacement of the product. If Rinnai determines that repair of a product is not possible, Rinnai will replace the product with a comparable product at Rinnai’s discretion. If a component or product returned to Rinnai is found to be free of defects in material or workmanship, or damaged by improper installation or damaged during return shipping, the warranty claim for product, parts and labor may be denied. * If the Heat Exchanger fails due to a defect in material or workmanship within the sixth (6) through the tenth (10) year from the date of purchase, Rinnai will make the following allowances toward the purchase of a replacement Heat Exchanger: Heat Exchanger Year of Failure Allowance 6 50% 7 40% 8 30% 9 20% 10 10% How do I get service? You must contact a state qualified/licensed contractor or authorized service provider for the repair of a product under this Warranty. For the name of a qualified/authorized service provider please contact your place of purchase, visit the Rinnai website (www.rinnai.us), call Rinnai at 1-800-621-9419 or write to Rinnai at 103 International Drive, Peachtree City, Georgia 30269. Proof of purchase is required to obtain warranty service. You may show proof of purchase with a dated sales receipt, or by registering within 30 days of purchasing the product. To register your appliance, please visit www.rinnairegistration.com. For those without internet access, please call 1-866-RINNAI1 (745-6241). Receipt of Registration by Rinnai will constitute proof-ofpurchase for this product. However, Registration is not necessary in order to validate this Warranty. What is not covered? This Warranty does not cover any failures or operating difficulties due to the following: • • • • • • • • • accident, abuse, or misuse alteration misapplication force majeure improper installation (such as but not limited to, condensate damage, improper venting, incorrect gas type, or incorrect gas pressure) improper conversion (including conversions for inventory adjustment) improper maintenance (such as but not limited to vent blockage) incorrect sizing any other causes other than defects in materials or workmanship This Warranty does not apply to any product whose serial number or manufacture date has been defaced. Limitation on warranties No one is authorized to make any other warranties on behalf of Rinnai America Corporation. Except as expressly provided herein, there are no other warranties, expressed or implied, including, but not limited to warranties of merchantability or fitness for a particular purpose, which extend beyond the description of the warranty herein and further Rinnai shall not be liable for indirect, incidental, special, consequential or other similar damages that may arise, including lost profits, damage to person or property, loss of use, inconvenience, or liability arising from improper installation, service or use. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you. Any implied warranties of merchantability and fitness arising under state law are limited in duration to the period of coverage provided by this limited Warranty, unless the period provided by state law is less. Some states do not allow limitations on how long an implied Warranty lasts, so the above limitation may not apply to you. This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Rinnai Corporation ES38 Manual 43 Rinnai America Corporation 103 International Drive Peachtree City, GA 30269 TOLL FREE: 1-800-621-9419 www.rinnai.us Tankless Water Heaters • • • • • • • • Residential and Commercial Applications Continuous Hot Water Up to 9.8 GPM High Energy Efficiency Propane or Natural Gas Internal or External Installation Digital Temperature Control Small, Compact Design Direct Vent Furnaces • • • • • High Efficiency Cool-to-the-touch Cabinet Blower Included Vent Terminal A Included Gas Conversion Kit Included Direct-Vent Fireplace, RHFE-750ETR • • • • • Up to 83% AFUE Energy Efficiency Zero-Clearance Installation Available in Four Options of Fronts Remotes and Fan Included Gas Conversion Kit Available Hydronic Air Handler • • • • • Register your product at www.rinnairegistration.com or call 1-866-RINNAI1 (746-6241) © 2009 Rinnai America Corporation Designed for Use with Rinnai Systems Domestic Hot Water Priority Optional Programmable Thermostat Zero Clearance to Combustibles Accommodates Standard Cased-Coils RHFE1004-0110X02 Printed in Japan 2009.12